Electrical terminal

Abstract: An electrical, female, box-shaped terminal (10) formed from a one-piece metal stamping and having a generally planar bottom (20), a pair of spaced sides (22,24), a first upper member defining a resilient contact arm (26) integral with one of the sides and extending transversely thereof towards the other side, and a second upper member defining a resilient back-up spring (28) integral with the other of said sides, which back-up spring (28) extends transversely of the sides and overlays the contact arm (26). The contact arm (26) has a forward end section (30) which extends downwardly towards, but spaced from, the bottom (20) to define a gap (32) therebetween into which a mating male blade terminal (12) can be inserted. The forward end section (30) is so shaped as to ensure that the contact arm (26) exerts a contact force upon the mating male blade terminal (12) in a direction that is substantially normal to the plane of the terminal (12). This arrangement allows the box-shaped terminal (10) of the invention to be used in conjunction with mating male blade terminals of differing thicknesses.

Description: The present invention relates to an electrical connector and, more particularly, to an electrical, female, box-shaped terminal having a resilient contact arm and which is of a design such that it can be connected to different thicknesses of mating male blade terminals. Heretofore, female, box-shaped electrical terminals have been provided. These terminals included either a single or double resilient contact arms for engaging a male mating-blade terminal when the latter was inserted therein. U.S. Patent Nos. 4,586,775 and 3,310,772, assigned to the General Motors Corporation, an assignee of the present invention, shows such terminals respectively. U.S. Patent No. 4,586,775 also shows a cantilevered support arm 48 for engaging the end of a resilient contact arm in the form of a tongue 44 to increase the contact force on a male blade terminal when the latter is inserted between the tongue 44 and a dimple 46 on the floor of the female terminal. Whilst the prior box-shaped female terminals have been highly successful in use, they nevertheless are primarily designed for receipt of male blade terminals of a standard nominal thickness dimension. However, in different countries in the world, the standard thickness of male blade terminals varies and thus different sizes of female terminals must be designed to accommodate each thickness of male blade terminal. Also, it is highly desirable to have a low insertion force required when connecting a male blade terminal to a box-shaped, female terminal whilst also having a relatively high contact force between the terminals to provide a connection therebetween which ensures good electrical conductivity. This is especially so when a plurality of male terminals contained in a multi-cavity insulated electrical connector body are simultaneously mated to a plurality of box-shaped, female terminals contained in a multi-cavity insulated electrical connector body. Whilst some trade-off between the insertion force and the mating contact force has to be made in designing electrical terminals, it has been found that, if the contact force between the male terminal and the female terminal is normal to the direction of insertion of the male blade terminal, a relatively high contact force can be obtained without creating a high insertion force. Accordingly, it is an object of the present invention to provide a new and improved box-shaped, female electrical terminal having a deflectable contact arm and which is constructed and arranged such that it can be used with mating male blade terminals of varying thicknesses whereby a single female terminal can be designed for global use. Another object of the present invention is to provide a new and improved female, box-shaped electrical terminal in which a mating male blade terminal can be mated thereto with a relatively low insertion force and yet have a relatively high normally-directed blade contact force to provide for good electrical conductivity therebetween. US-A-5112254 discloses an electrical terminal in accordance with the preamble of claim 1. US-A-4919628 discloses a tab receptacle with fixed beam contacts. US-A-4834681 discloses an electrical terminal having internal cantilevered side walls. An electrical terminal in accordance with the present invention is characterised over US-A-5112254 by the features specified in the characterising portion of claim 1. The objects and advantages of the present invention are achieved by providing a female electrical terminal which comprises a one-piece, stamped metal member which has a forward, generally box-shaped main body portion and a rearward conductor-engaging portion. The main body portion comprises a generally planar bottom, a pair of spaced sides, a first upper member defining a resilient contact arm integral with one of the sides and extending transversely thereof towards the other side, and a second upper member defining a resilient back-up spring integral with the other of the sides and extending transversely of the sides and overlying the contact arm. The contact arm has a forward end section extending downwardly towards, but spaced from, the bottom to define a gap therebetween. The contact arm exerts a resisting force, when deflected by a mating male terminal, upon the male terminal being slidably inserted between the bottom and the forward end section of the female terminal. The female terminal also includes a substantially rigid tab extending transversely from the other side and which is engageable with the contact arm along its underside to control the spacing of the gap between the contact arm and the bottom of the terminal. The back-up spring is engageable with the contact arm and provides a further resilient resisting spring force in addition to the spring force exerted by the forward section of the contact arm when it is mated to a mating male blade terminal. The advantages of the above terminal are that it is capable of receiving mating male blade terminals of varying thicknesses. By controlling the dimension of the gap between the contact arm and the bottom of the terminal, the terminal provides a sufficient engaging force with even a minimum thickness of male blade terminal so that good electrical conductivity is obtained between the male blade terminal and the female terminal. Another advantage is that the contact between the resilient contact arm and the male blade terminal is such that it provides a resisting force directed against the male blade terminal, when being inserted into the female terminal, which is normal, i.e., perpendicular to the plane of the male blade terminal. This not only provides a sufficient contact force for good electrical conductivity, but also provides for a relatively low insertion force since the resisting force is directed normal to the direction of the insertion force. The present invention further resides in various novel constructions and arrangement of parts, and further objects, novel characteristics and advantages of the present invention will be apparent to those skilled in the art to which it relates and from the following detailed description of the illustrated, preferred embodiments thereof made with reference to the accompanying drawings forming a part of this specification and in which similar reference numerals are employed to designate corresponding parts throughout the several views, and in which: Figure 1 is a perspective view of a female, box-shaped terminal of the present invention; Figure 2 is a longitudinal, cross-sectional view taken approximately along the lines 2-2 of Figure 1; Figure 3 is a cross-sectional view taken along the lines 3-3 of Figure 1; Figure 4 is a top plan view of the electrical terminal shown in Figure 1; Figure 5 is an end elevational view looking in the direction of the arrow 5-5 of Figure 4; Figure 6 is a cross-sectional view taken approximately along the lines of 6-6 of Figure 4; Figure 7 is a top plan view of the electrical terminal of the present invention and showing the same in blank form prior to being folded to the configuration shown in Figure 1; Figure 8 is a fragmentary cross-sectional view of a connector insulator body and showing the terminal of Figure 1 connected thereto; Figure 9 is a perspective view of a second embodiment of a female electrical terminal of the present invention; Figure 10 is a fragmentary longitudinal, cross-sectional view taken approximately along the lines 10-10 of Figure 9; Figure 11 is a cross-sectional view taken approximately along the lines of 11-11 of Figure 9; Figure 12 is a fragmentary top plan view of the electrical connector shown in Figure 9; and Figure 13 is a top plan view of the electrical connector of the present invention shown in Figure 9, showing the same in blank form prior to being folded. Figures 1-8 disclose a first embodiment of a novel female box-shaped terminal 10 of the present invention which is adapted to be mated with a male blade terminal 12. The electrical terminal 10 is a one-piece metal member of relatively thin gauge metal stock and comprises, in general, a forward, generally box-shaped main body portion 14 and a rearward, conductor-engaging portion 16. The main body portion 14 comprises a generally planar bottom 20, a pair of spaced sides 22, 24 extending transversely to the bottom 20, a first upper member defining a resilient, deflectable contact arm 26 integral with the side 22 adjacent its upper end and extending transversely thereof towards the other side 24, and a second upper member defining a resilient, deflectable back-up spring 28 integral with the side 24 adjacent its upper end and extending transversely thereof towards the other side 22 and overlying the contact arm 26. The contact arm 26 has a forward end section 30 which extends downwardly towards, and is spaced from, the bottom 20 to define a gap 32. The gap 32 has a transverse dimension, shows as width W, which is controlled by a substantially rigid tab 34 integral with the side 24 and which engages the contact arm 26 along its underside. The forward section 30 of the contact arm 26 exerts a normally, perpendicularly-directed resisting force when deflected by the mating blade terminal 12 upon the latter being slidably inserted between the bottom 20 and the forward end section 30 of the terminal 10. The back-up spring 28 is engageable with the contact arm 26 and provides a further resisting spring force directed normally of the male blade terminal 12 in addition to the spring force exerted by the forward section 30 of the contact arm 26 when being mated to the mating male terminal 12. The generally planar bottom 20 of the forward portion 14 of the electrical terminal 10 includes a raised dimpled portion 40 which is located directly beneath the forward end section 30 of the resilient contact arm 26. The raised area 40 strengthens the bottom floor 20 of the terminal and provides a flat surface for slidably receiving and mating with the male blade terminal 12. The forward section 30 of the resilient contact arm 26 includes a leg portion 42 which extends downwardly towards the raised contact area 40 and an upwardly-extending leg portion 44 extending towards a forward end 45 of the terminal 10. The leg portions 42, 44 are integrally connected via a bight portion 46 having a curved, rounded undersurface 48 located directly above the raised area 40 on the bottom 20. This curved surface 48 provides a thin, narrow width contact with the male blade terminal 12 extending transversely of the terminal 10 when the male blade terminal 12 is inserted between the raised portion 40 and the bight portion 46 of the forward end section 30 of the resilient contact blade 26. The sides 22, 24 extend transversely, preferably normal, to the bottom 20 and are parallel to each other. The sides 22, 24 are respectively integrally connected to the resilient contact blade 26 and the resilient back-up spring 28 along their rearward sections, as viewed in Figure 1. The side 24 at its forward section 50, as shown in Figure 1, is integral with a top 52, which top extends normal to, and transversely thereof, the upper end of side 24. Top 52 has a flat portion 54 adjacent its forward end and a raised, struck-up portion 56 forming a tang at its rearward end. As best shown in Figure 8, the tang 56 defines a lock shoulder 58 facing rearwardly of the terminal and is adapted to engage a deflectable lock finger 60 in a cavity 61 of a connector body 62, as shown in Figure 8, when the terminal 10 is connected to the connector body 62, and in a conventional manner well known to those skilled in the art. The top 52 also includes a reversely-bent portion 66 which extends downwardly and rearwardly towards the leg portion 44 of the forward end section 30 of the resilient contact arm 26, as best shown in Figure 2. The rearwardly and downwardly-directed portion 66 provides a guide for entry of the male blade terminal 12 into the female terminal 10. The top 52 covers the contact area between the male terminal 12, the forward end section 30 and the bottom 20 and thus aids in preventing contamination of the contact area. The top 52 also protects the forward end section 30 of the contact arm 26 from being accidentally deflected or moved so as to change the width W of the gap 32. The side 24 also includes a vertically-extending tang in the form of tab 70. The tab 70 is a guide tab which is slidably received in a slot 71 in the cavity 61 of the mating connector body 62 and provides for properly orienting the female terminal 10 in the connector body 62. The side 22 at its forward end includes a tab 72 which is bent transversely of the side 22 and over the top 52. This maintains the square box shape of the forward end 45 of the terminal 10 and stiffens the forward end of the terminal 10. The positioning tab 34 is substantially rigid and is integral with the side 24 at its upper end. The tab 34 extends normal to the side 24 and engages the underside of the resilient contact arm 26 along its longitudinal free side portion 76 remote from the side 22, as shown in Figure 6. The contact arm 26 is bent to be step-shaped in cross-section so that the free side portion 76 is flat to engage the flat contact tab 34. The tab 34 accurately controls the vertical dimension, shown as width W, of the gap 32 between the bight portion 46 and the raised portion 40 of the bottom 20. The back-up spring 28 has a rearward section 79 which is parallel with the contact arm 26 and a forward section 80 which extends downwardly at an angle towards the top side of the resilient contact arm 26 so that its forward end 82 engages the contact arm 26. The back-up spring 28 includes a dimple 86 in its rearward section 79 which is spaced from, but adapted to engage, a raised portion 90 on the contact arm 26. From the foregoing, it should be apparent that the electrical connector 10 can be mated with its mating male blade terminal 12 by inserting the male blade terminal 12 into the gap 32 between the bottom 20 and the bight portion 46 of the forward end section 30 of the resilient contact blade 26. When the male blade 12 is inserted therebetween, the forward end section 30 is caused to be deflected upwardly, which in turn, due to its engagement with the forward section 80, causes the back-up spring 28 to be deflected upwardly. The force exerted on the male blade terminal 12 will be normal to the direction of insertion of the male blade terminal 12 and will be exerted on the male blade terminal at the interface between the bight portion 46 and the raised portion 40. The positioning of the tab 34 can be such as to provide for a minimum gap 32, i.e., width W, to accommodate a male blade terminal 12 having a minimum thickness. If male blade terminals 12 of larger thicknesses are inserted, the terminal 10 can accommodate them as a result of the resiliency of the contact arm 26 and back-up spring 28. Since the forces resisting insertion of the male blade terminal 12 are directed normally of the male blade terminal, the insertion force required for mating the two terminals 10 and 12 is minimised. It should be noted that, if a larger thickness male blade terminal 12 is mated to the female terminal 10, and the forward end section 30 and back-up spring 28 are deflected a predetermined extent, the dimple 86 will engage the raised portion 90 on the contact arm 26. This will increase the stiffness of the contact arm 26 and back-up spring 28 and thus provide further resistance. Additionally, it should be noted that the gap 32 can be readily adjusted by controlling the position of the cross tab 34 relative to the bottom 20. Thus, one gap dimension W could be employed for mating with a given thickness male blade terminal 12 and if a much larger thickness male blade terminal 12 were contemplated to be used, the stamping die for forming the terminal 10 could be slightly modified to re-position the tab 34 vertically relative to the bottom 20, as viewed in Figure 2, to cause the width W of the gap 32 to be altered. As shown in Figure 7, the electrical terminal 10 is made in one-piece from flat metal stock, such as brass, and is initially stamped to the configuration shown in Figure 7. Note that the stamping for the main portion 14 of the terminal 10, as viewed in Figure 7, is generally rectangular in shape and thus of a shape which provides for minimum wastage. The terminal 10 is stamped to the configuration shown in Figure 1 by first stamping in the raised portion 40, raised portion 90 and end section 30 and the dimple 86, in the bottom 20, contact arm 26 and back-up spring 28, respectively. The terminal 10 is then formed by bending up the sides 22, 24, then bending over the tab 34 through an angle of 90°, and then bending the resilient contact arm 26 to lie over and into engagement with the tab 34, and then bending the resilient back-up spring 28 to lie over the top of the resilient contact arm 26. At the same time, the portion 66 at the forward end of the blank is reversely bent and then the top 52 is bent to lie over the bottom 20 and thereafter the tab 72 is bent over the top 52 to complete the formation of the terminal 10. The rearward portion 16 of the terminal includes spaced crimping wings 94, 96 which are adapted to be crimped onto a bare wire portion and an insulated portion of a wire conductor (not shown), and in a manner well known to those skilled in the art. The contact arm 26 and the back-up spring 28 at their rearward ends 98 and 99, respectively, are vertically aligned, as shown in Figure 2. These ends 98, 99 could be used as further lock shoulders to receive a terminal portion assurance member (not shown) which could be inserted transversely of the connector body 62 through a transverse opening (not shown), if desired. Figures 9-13 show an alternative embodiment of a novel electrical terminal 10' of the present invention. The electrical terminal 10' is identical to the terminal 10 and hence, the same reference numerals will be employed to designate corresponding parts throughout the views. The terminal 10' differs from the previously described terminal 10 in that the tab 72 of the terminal 10 has been eliminated and in its stead the side 22 has a raised portion 100 provided with a window opening 102. This window 102 receives a transverse tab 104 integral with the top 52 and with the tab 104 being received through the window 102 to control the square box shape at the forward end 45 of the terminal 10'. Also, the terminal 10' has a forward end 106 integral with the top 52 which is merely bent downwardly towards the bottom 20 instead of being reversely curled inwards like portion 66 of the terminal 10. Another difference is that it has a somewhat different contact arm 26'. The resilient contact arm 26' has a forward section 108 and rearward section 110 which is reversely bent onto itself, so as to be juxtaposed thereto, as indicated by reference numeral 112 in Figure 11, prior to being bent to lie over the tab 34. The rearward section 110 is double the width of the remainder of the contact arm 26 so that it can be folded onto itself. This increases the strength of the resilient contact arm 26' at its rearward portion which engages the back-up spring 28. The double folded rearward section 110 replaces the dimples 86, 90 in the terminal 10. As shown in Figure 13, the forward section 108 and half the rearward section 110 of the resilient contact arm 26' are first bent over and folded along line 120 over and onto the other half of the rearward section 110. The contact arm 26' is then folded along line 122 so as to be normal to the side 22 and with the forward section 108 engaging the tab 34. In all other respects, the electrical terminal 10' of this embodiment is the same, operates in the same manner and functions to achieve the same results as the terminal 10 previously described. Although the illustrated embodiments hereof have been described in great detail, it should be apparent that certain modifications, changes and adaptations may be made in the illustrated embodiments which could also come within the scope of the claims of the present application. The disclosures in United States patent application no. 040,310, from which this application claims priority, and in the abstract accompanying this application are incorporated herein by reference.

Claims: An electrical terminal (10;10') which is adapted to be connected to an electrical conductor, said terminal (10;10') comprising: a one-piece metal member which has a forward, generally box-shaped, main body portion (14), a rearward, conductor-engaging portion (16), and a deflectable resilient contact arm (26;26') wherein the box-shaped main body portion (14) comprises a generally planar bottom (20), a pair of spaced sides (22,24) extending transversely of said bottom (20), a first upper member defining said deflectable contact arm (26,26') integral with one of the sides (22) adjacent its upper end and extending transversely thereof towards the other side (24), and a second upper member defining a deflectable back-up spring (28) overlying said contact arm (26;26'), said contact arm (26;26') having an end section (30) extending downwardly towards, but spaced from, said bottom (20) to define a gap (32) therebetween, said contact arm (26;26') exerting a resisting force when deflected by a mating male terminal (12) upon the latter being slidably inserted between said bottom (20) and said end section (30) of said terminal (10;10'), said back-up spring (28) being engageable with said contact arm (26;26') and providing a further resisting spring force in addition to the spring force exerted on said mating male terminal (12) by the end section (30) of the contact arm (26;26') when contacting said mating male terminal (12); characterised in that the deflectable back-up spring is integral with the other (24) of the sides adjacent its upper end and extends transversely thereof towards the one side (22); in that the end section (30) of the contact arm (26;26') is directed in the forward direction of the terminal; and in that a substantially rigid tab (34) extends transversely of said other side (24) and is engageable with said contact arm (26;26') along the underside thereof to control the spacing of said gap (32) between the contact arm (26;26') and said bottom (20). An electrical terminal (10;10') according to claim 1, in which the one-piece metal member is formed from relatively thin gauge metal stock, and has said forward, generally box-shaped main body portion (14) and a rearward crimping wing portion (16,94,96) which is adapted to be crimped to an electrical connector; said contact arm (26;26') deflects and exerts said force generally normal to the mating male terminal (12) when the latter is connected between said bottom (20) and said forward end section (30); and said deflectable back-up spring (28) exerts said further resisting spring force generally normal to said mating male terminal (12) in addition to the spring force exerted on said mating male terminal (12) by the forward end section (30) of the contact arm (26;26') when contacting said mating male terminal (12). An electrical terminal (10;10') according to claim 2, in which said deflectable contact arm (26;26') has a forward end section (30) which includes a first leg portion (42) extending downwardly towards said bottom (20), a second leg portion (44) extending upwardly towards a forward end (45) of the terminal (10;10') and a bight portion (46) between said leg portions (42,44), said bight portion (46) having a rounded undersurface (48) which is spaced from said bottom (20) to define said gap (32) and with the bight portion (46) adapted to slideably engage said mating male blade terminal (12) when the latter is inserted between said bottom (20) and said forward end section (30). An electrical terminal (10;10') according to claim 3, in which said terminal (10;10') includes a top (52) at its forward end (45) which is integral with one of the sides (22,24) and which overlies said bight portion (46) and said second leg portion (44) of said forward end section (30) of said contact arm (26;26'). An electrical terminal (10;10') according to claim 4, in which said top (52) is struck-up at its rearward end (56) to define a lock shoulder (58) which is adapted to engage a deflectable lock finger (60) on a plastics connector body (62). An electrical terminal (10) according to claim 4, in which said terminal (10) at its forward end (45) also has a tab (72) integral with the other of its sides (22,24) which is bent over the top (52) to further strengthen the forward end (45) of the terminal (10). An electrical terminal (10') according to claim 4, in which said top (52) has a projecting tab (104) which extends through an opening (102) in the other side (22) of the terminal (10') to strengthen the forward end (45) of the terminal (10'). An electrical terminal (10) according to claim 3, in which said contact arm (26) and said back-up spring (28) adjacent the rearward ends thereof have aligned raised portions (86,90) which are engageable with each other. An electrical terminal (10') according to claim 3, in which said contact arm (26') has rearward end sections (110) which are folded to be juxtaposed to one another so as to increase the rigidity of the rearward end of the contact arm (26'), said rearward end sections (110) being engageable with said back-up spring (28) when the contact arm (26') is deflected. An electrical terminal (10;10') according to claim 3, in which said bottom (20) has a flat raised portion (40) located beneath said bight portion (46) of said forward end section (30) of said contact arm (26;26') which raised portion (40) is adapted to engage one side of said mating male terminal (12) when the latter is inserted between the bight portion (46) and said raised portion (40).

Inventors: BUNGO EDWARD MARTIN, CHUPAK JOHN MARVIN, HALBACH PAUL GERARD, MODEL MICHAEL, PAUSS LUDWIG, BUNGO, EDWARD MARTIN, CHUPAK, JOHN MARVIN, HALBACH, PAUL GERARD, MODEL, MICHAEL, PAUSS, LUDWIG
Applicants: GEN MOTORS CORP, GENERAL MOTORS CORPORATION
Application year: 1994
Main classification: H01R13
IPC codes: H01R13